Surgical pad and method of making the same



Nov. 13, 1962 w. M. scHoLL 3,063,448

SURGICAL .PAD AND METHOD IoF MAKING THE SAME Filed oct. 21, 195s 2 sheets-'sheet 1 W/LL/M M SCHOLL Nov. 13, 1962 w. M. scHoLl. "135063,44'8

SURGICAL PAD AND METHOD oF MAKING THEssAME Filed oct. 21. 1958 fzjfsheefts-sheetz 4.zz/'Enfar W/LLMM M. SCA/OLA Unite tates atet ffice 3,il3,448 SURGICAL PAD AND METHGD OF MG THE SAME William M. Scholl, 2li-213 W. Schiller St., Chicago, lil. Fiied ct. 21, 1958, Ser. No. 768,605 12 Siairns. {CL 12S-53) This invention relates to improvements in a surgical pad and method of making the same, and more particularly to surgical pads for direct attachment to the human body for alleviation of various aiictions, such as coms, calluses, bunions, bruises, abrasions, lacerations, and substantially any form of injury or afliiction from which it is desired to keep pressure from apparel and the like, and also to a new and novel method of making such surgical pads, although the invention may have other uses and purposes as will be apparent to one skilled in the art.

in order to give relief from pressure of apparel on an injury or affliction, it is necessary to provide a cushion around the affliction and thus transfer the pressure of apparel to the healthy tissue surrounding the affliction or painful area, and this must be accomplished without creating any new or additional irritation to that healthy tissue.

In the past, manyand various types of surgical pads have been developed, bu-t in many cases these formerly known pads possessed abrupt edges at the pad boundary where apparel likely to cause pressure is initially elevated and maintained away from the aiiiiction. lf the pad was sufficiently firm to sustain the pressure, such abrupt edges caused additional irritation on the healthy tissue around the affliction. In other instances, these formerly known pads, if capable of properly eliminating pressure from relatively tight or firm apparel such as shoes, were not capable of sustaining the pressure over a period of time, but were of such soft texture that matting, compacting, squashing or spreading occurred so that after relatively short usage the pressure was not properly eliminated. Further, pads of this type heretofore known were frequently not of a Waterproof character, did not dry quickly if wetted, and were relatively short lived.

With the foregoing in mind, it is an important object ot the instant invention to provide a, surgical pad having no abrupt bounding edge whatever, but which is possessed of a substantially at bot-tom surface, and a Well rounded top surface decreasing in thickness in all directions from an intermediate high region.

Another feature of the instant invention is the provision of a surgical pad which, while suihciently yielding to eliminate any irritation even from relatively heavy pressure, is also so constructed that the pad itself is nonspreadable laterally under pressure, whereby While the pad may decrease in thickness due to pressure, it nevertheless is sufficiently firm in construction as not to materially yield beyond a certain degree, and is composed of such material that it will always recover its original size and shape immediately upon the release of pressure, whereby no permanent compacting or liattening can result.

Another object of the instant invention is the provision of a surgical pad which may be of substantially any size or shape, and which is provided with an afliiction receiving opening, the pad comprising an intermediate thick layer of cushioning material disposed between upper and lower films, which are secured together along the bounding edge of the pad and enclose the cushioning material, the upper lm being drawn into skintight relationship with the upper surface of the cushioning material.

Still another object of the instant invention is the provision of a surgical pad comprising a bottom iilm having a pressure sensitive adhesive thereon, a pad body of relatively dense thermoplastic foam, and .a top cover lm disposed in skintight relationship over the upper surface of the pad body, `and heat sealed to the lower film along the bounding edge of the surgical pad.

The instant invention also contemplates a new and novel method of making a surgical pad or surgical pads, including the steps of completely forming the pad with a plurality of heat sealing operations on a facing sheet, and then eliminating the Waste leaving the nished pads remain-ing on the same facing sheet until removed ultimately by the user.

My new and novel method of making surgical pads also includes the steps of forming and shaping a pad body, preforrning a cover film with a recess -therein complemental to the pad body, placing the cover film over the pad body, and then securing the cover film in position on the body in skintight relationship thereto.

While some of the more salient features, characteristics and advantages of the instant invention have been above pointed out, others will become apparent from the following disclosures, taken in conjunction with the accompanying drawings, in which FIG. 1 is a plan view of a number of surgical pads in the course of formation;

FIG. 2 -is a greatly enlarged fragmentary vertical sectional view taken substantially as indicated by the section line ll-li of FIG. l, looking in the direction 0f the arrows, and illustrating certain initial steps in the method of forming the pads;

FIG. 3 is a reduced plan view illustrating a further step in the production of the pads;

FIG. 4 is a top plan View of a preformed cover sheet;

FIG. 5 is a greatly enlarged fragmentary vertical sectional view ofthe character `of FIG. 2, but illustrating the placing of the preformed cover sheet of FIG. 4 in position for securement to the pads;

FIG. 6 is a view similar in character to FIG. 5 illustr'ating the attachment of the preformed cover sheet;

FIG. 7 is a top plan view of a finished pad removed from the facing sheet;

FIG. 8 is a central vertical sectional view through the structure of FIG. 7;

FIG. 9 is a view similar in character to FIG. 8, but illustrating a pad of slightly different construction;

FIG. l0 -is a reduced plan view of a pad of slightly different formation; and Y FIG. l1 is a plan view of a pad embodying principles of the instant invention, but of still a further formation.

As shown on the drawings:

The instant invention may best be described by wayof the process of making it. Looking now at FIGS. 1 and 2 of the drawings, a facing sheet 1 is irst disposed or spread upon any suitable surface and, since heat sealing dies are to be ultimately used, preferably of the electronic type, the surface upon which the facing sheet l is disposed may be a dielectric or insulating sheet such as a urea-formaldehyde condensation product, for example. This facing sheet ultimately acts as the temporary protective covering -for theresultant pads, from which the pads are removed vat the time of use. Since the pads possess a pressure sensitive adhesive surface, it is necessary that the facing sheet have a release coat or surface thereon. It is also desirable that this facing sheet be not injured in any respect during the heat sealing operations performed on the laminae during the making of the pads. Accordingly, the facing sheet may satisfactorily be a rubber impregnated paper treated with a sodium sulfate wetting agent, and then coated with a nitro-cellulose lacquer. Such a facing sheet will not be injured by the heat sealing operations, and will permit the ready removal of a finished pad therefrom. The

3V above composition of the facing sheet is given by way of example, and not by way of limitation, since paper impregnated and treated with other substances may also be satisfactory.

Over the facing sheet 1, a iilrnlike sheet 2 is disposed. This Viilmlike sheet 2 is preferably a thermoplastic lilm suitable for heat sealing purposes, and one substance highly satisfactory is a polyvinyl chloride film. The iilm or sheet 2,Y before Ibeing placed in position on the facing sheet 1, has been provided with a pressure sensitive adhesiveundersurface 3` by means of which the iilm is attached to the facing sheet, as clearly seen in FIG. 2.

After the film 2 has been placed in position, a considerably thicker layer 4 of cushioning material is placed on top of the lilm. This layer 4 is preferably a thermoplastic foam, of relatively dense consistency, and which is subject to heat sealing. One satisfactory substance is polyvinyl chloride foam. Then, electronic die means, which Ymay carry a plurality of individual die members, is brought down upon the foam layer 4. Each die element is so shaped as to define the bounding contour of a surgical pad, and the die element is brought down with some pressure suicient to force a relatively sharp edge portion of the die into the foam. This results in heat sealing the foam to the film 2 around the bounding edge of the resultant pad in a seam indicated at 5, and the vstructure of the facing sheet 1, as above described, is such that the electronic wave will penetrate both the filmV 2 and the adhesive spread 3; thus, forming a line of severance 6 at the time the seam 5 is made. The action of the die thus defines a pad body 7 having a rounded top surface 8, and the body decreases in thickness in all directions from a high central portion 9 to the line edge heat seal seam 5. After one or more o-f the pad bodies- 7 have been so formed, the wasteAV part 4of the sheet 4 is readily removed around the lines of severance 6, leaving a number of the pad bodies 7 in spaced relationship on the ilm 2 which is not then removed with the waste of the cushion sheet 4, whereupon the structure will appear as seen in FIG. 3.

At any desiredrtime and in any desired location, a thin lmlike cover sheet 10 may be preformed to provide in it a plurality of recesses or sockets as indicated at 11 each of which is complemental in shape to one of lthe pad bodies 7. This sheet 4 may satisfactorily be f an extremely thin polyvinyl chloride film or equivalent material susceptible to heat sealing and may be vacuum drawn over a mold of the same shape as the desired shape ofthe pad body. Preferably, the depth of each recess 11 is slightly less than the actual height of the viously operated. This Ycauses va slight stretching of theportion 11 of the film over a pad body 7 in order to establish a heat seal seam 12 which unites the cover film with thek bounding edge of the pad body and the film 2. The forming of this heat seal seam 12 does not disturb the previous line of severance 6 and of course provides a severance line in ythe cover lm 1,0 as well. The establishment of the heat seal seam E2 also causes a. slight stretching of the portion 11 of the cover sheet 10, so that that cover is in skintight relationship with the pad body 7. It will also be noted that the pad body is now confinedV between theY bottom and top sheets or films 2 and 10, and although those films are slightly stretchable lbut always recover, the pad body which eliminates pressure from apparel is prevented from spreading laterally under pressure, and since it cannot permanently compact and lby means of the pad constuction cannot compress beyond a desirable extent, it will always effectively relieve an afiction from apparel pressure.

Preferably each surgical pad is provided with an affliction receiving opening or recess. With a pad of the character of a corn pad or the like, such opening may -be in the form of an aperture, whereas in other forms of pads it might be in the form of a notch. In the event the cover is to overlie and cover the affliction receiving opening, the opening is provided in the pad structure prior to the application of the cover sheet 1t). lf the opening is to extend entirely through the cover sheet as well as the pad body and lm 2, the opening is provided after the application of the cover sheet l0.

After the application of the cover sheet 10, the waste portion of the cover sheet, the film 2 and its adhesive undersurface is removed along the lines of severance 6, leaving the finished pads remaining on the facing sheet 1 which may be cut to any desirable size to carry as many pads as may be desired for a single package. As stated above, the facing sheet has not been changed in any manner by the heat sealing operations performed in making the pads.

In FIGS. 7 and 8 I have illustrated a form of pad highly desirable for the `alleviation of aiflictions such as corns or calluses. In this. instance, the alliiction receiving opening extends entirely through all of the structure of the pad. This opening may be provided 'by punching through the structure as indicated by the dotted lines 13 in FIG. 6, thus providing an aperture 14 through. the pad. The pad is shown removed from the facing sheet 1, lready for use. In use, the pad may be applied directly to the body by virtue of the adhesive undersurface 3, with the aliction disposed inside the aperture 14. It will be especially noted that there will be a gradual uplifting of an article of apparel, such as a shoe or the like, from the immediate region of the alliietion by virtue of the upper contour of the pad. As stated above, the pad cannot collapse or spread sidewise sufficiently for the pressure to come too close to the afiliction itself. Thus, the pressure of the apparel is transferred in a gentle and easy Vmanner to healthy tissue surrounding the affliction, and there are no abrupt edges on the pad itself to cause any added irritation to that healthy tissue.

In YFIG. 9 I have shown a pad of similar construction to that of FIGS. 7 and 8, lbut in this instance the aiiction receiving opening 14av is provided in the pad prior to the application of the cover sheet or film 10, and the portion 11 of the cover sheet 1i) extends over the opening 14a. A pad of this character is highly desirable for use lwhere exudation may come from the Vafliiction itself, or it is desired to use -a medicament over Vthe aiiiiction, and eliminate the possibility of such coming in contact with articles of apparel.

InV FIG. l0 I have illustrated a surgical pad made in accordance with the instant invention, of a dilerent shape, the pad being shown of reduced size, and being of the character to lie along Ythe side of a toe, and alleviate an affliction such as a -bunion or thev like. In this instance, the pad lbody generally indicated by numeral 15 is of the shapeof an elongated oval, and is provided with an offset aiiiiction receiving opening 16. The top surface of the finished pad is rounded as above described.

In FIG. ll I have illustrated a still different shape of pad, generally indicated by numeral 17, with an affliction receiving opening in the form of a notch 18 extending inwardly from one end of the pad. In this instance, the heat seal seam joining the two films and body portion of the pad will extend around the contour of the opening Y 18 as well as the remaining bounding edge of the pad.

From the foregoing it lwill be apparent that l have provided a novel surgical pad that will effectively protect an aiiction from external pressure and yet cause no added irritation, which is economical to manufacture, which is extremely durable and 4long lived in use, and may be made in substantially any size and shape consistent with particular afliictions to be treated.

It will 'be understood -that modifications and variations may be eected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

1. The method of making a surgical pad, including the steps of superposing a film-like sheet of thermoplastic and a relatively dense and thicker sheet of thermoplastic foam, defining, shaping and heat sealing a pad body from the foam sheet around its bounding edge to said filmlike sheet and forming a line of severance at the heat seal seam, stripping the waste foam from around said pad, placing a preformed thin thermoplastic cover film over said pad body, and heat sealing said cover film to said film-like sheet while drawing the same into skintight relationship with said body.

2. The method of making a surgical pad, including the steps of forming a pad body having a fiat bottom and rounded top from a sheet of thermoplastic foam, preforming a thermoplastic film complemental to said pad body, placing said preformed thermoplastic film over said body, and heat sealing said film to said body.

3. The method of making a surgical pad, including the steps of forming a pad body of cushioning material on a thermoplastic film bottom member, preforming a thermoplastic film complemental to said pad body, covering said body with said preformed thermoplastic film, and heat sea-ling said preformed film to the first said film around said body.

4. The method of making a surgical pad, including the steps of shaping a pad body with a fiat bottom face and a rounded upper surface from a sheet of thermoplastic foam, placing a thermoplastic film having a `deviation preformed therein complemental to said pad body over the pad body, and heat sealing the preformed portion of the film to said pad body along the bounding edge thereof.

5. The method of making a surgical pad, including the steps of forming a pad body of cushioning material on a thermoplastic film bottom member, preforming va thermoplastic film complemental to said pad body, covering said body with said preformed thermoplastic film, and heat sealing said preformed film to the first said film `around said body, and cutting through said pad to provide an affliction receiving opening therein.

6. The method of -making a surgical pad, including the steps of forming a pad body of cushioning material on a Ithermoplastic film bottom member, cutting said film bottom member and said body to provide an affliction receiving opening, preforming a thermoplastic film complementa] to said pad body, covering said body with said preformed thermoplastic film, and heat sealing said preformed film to the first said film around said rbody.

7. The method of making :a surgical pad, including the steps of shaping a pad :body to a desired contour from cushioning material on a film-like sheet carrying a pressure sensitive adhesive on its undersurface, placing a film-like sheet having a preformed portion complemental to the shape of the pad body over the pad body, and securing said sheets together only around the edge of said body `while stretching said preformed portion into skin-tight relationship with said body.

8. The method of making a surgical pad, including the steps of shaping a pad body to a desired contour from cushioning material on a film-like sheet carrying a pressure sensitive adhesive on its undersurface, placing a filmlike sheet having a preformed portion complemental to the shape of the pad body over the pad body, heat sealing said sheets together around said body While stretching the upper sheet over said body and simultaneously forming a line of severance in said sheets at the heat `seal seam.

9. The method of making surgical pads, including the steps of superposing in bottom to top order a facing sheet having a release coating, a thermoplastic film carrying pressure sensitive adhesive on its underface, and a considerably thicker sheet of thermoplastic foam, simultaneously shaping pad bodies `from said foam sheet and heat sealing each body along its bounding edge to said film and providing a line of severance through the film, removing the waste of the foam sheet from between the pads,

reforming a thin thermoplastic cover film with recesses complemental to the pad bodies, laying the preformed film over the pad bodies, heat sealing the cover film to the bounding pad edge of the first said film while stretching the recessed portions over the pad bodies and providing a line of severance in the cover film, and removing the Waste of both films leaving the pads on the facing sheet.

10. The method of making surgical pads, including the steps of shaping a plurality of pad bodies carrying pressure sensitive adhesive on their underfaces on top of a facing sheet having a release coat, preforrning a thermoplastic film with recessed portions complemental to said pad bodies, heat sealing said recessed portions to the bases of said pad bodies, simultaneously forming a line of severance around the heat seal seam, and stripping the waste of the preformed film.

11. A surgical pad comprising a thermoplastic film carrying a pressure sensitive adhesive on its underface, a thermoplastic cushion body on said film, a thin thermoplastic cover film having a dome formation preformed therein complemental to said body disposed over said body in skin-tight relationship, and a fine line heat seal seam holding said films fused together around said body.

l2. ln a surgical pad, a preformed thermoplastic cushioning body of generally dome shape thinning in all directions from a central high region, a thin thermoplastic cover film having a dome formation preformed therein complemental to said body but initially of slightly less depth than the height of the body, and a fine line heat seal seam holding said film and body fused together and maintaining said film in skin-tight relationship to said body.

References Cited in the file of this patent UNITED STATES PATENTS 720,812 Johnson Feb. 17, 1903 1,996,835 Scholl Apr. 9, 1935 2,081,715 Scholl May 25, 1937 2,585,691 Scholl Feb. 12, 1952 2,712,311 Scholl July 5, 1955 2,716,625 Scholl Aug. 30, A1955 2,783,474 Campagna Mar. 5, 1957 2,854,974 Ashton et Val Oct. 7, 1958 2,878,153 Hacklander Mar. 17, 1959 2,953,130 schon c sept. 2o, 1969 

1. THE METHOD OF MAKING A SURGICAL PAD, INCLUDING THE STEPS OF SUPERPOSING A FILM-LIKE SHEET OF THERMOPLASTIC AND A RELATIVELY DENSE AND THICKER SHEET OF THERMOPLASTIC FOAM, DEFINING SHAPING AND HEAT SEALING A PAD BODY FROM 